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23.09.2010MAN Diesel & Turbo < 1 >
Nature of the maritime maintenance problem,
seen from an engine manufactures point of view.
Michael Petersen
Senior Manager
Engine Management / PrimeServ
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Agenda
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Life cycle cost is the total costfrom design to disposal, theobjective of LCC is to choose themost cost effective approach, sothat the lowest long term cost ofownership is achieved!
Maintenance seen as a life cycle cost.
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Maintenance seen as a life cycle cost.
Procurement cost
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Procurement cost is widely usedas the primary (and sometimesonly) criterion for equipment,
spare parts or system selection(i.e. the cheaper the better).
However, the major costs lie inthe care and operation of
equipment during its life.
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CBOCondition Based Overhaul Strategy,
Largely extended Overhaul intervals.
Never touch a well running unit
Condition Based Overhaul (CBO)
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Condition Based Overhaul (CBO)
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Condition Based Overhaul (CBO)
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Condition Based Overhaul (CBO)
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The Objective is:
Tankers and similar vessels
3 - 5 years operation without immobilisation, equal to
18 / 32,000 hours between major overhauls (dock todock)
Container, bulkers and similar vessels
Up to 5 years between major overhauls of bearings,turbochargers, pistons, cylinders and piston rings.
Condition Based Overhaul (CBO)
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Status
Major Overhauls / Inspections,which require immobilisation:
Bearings
Turbochargers
Cylinder units
Fuel pumps
Exhaust valves
Condition Based Overhaul (CBO)
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Condition Based Overhaul (CBO)
How to judge when overhaul is necessary?
2-stroke engine's can be inspected by open-up
the doors, go in, see, check and record.
In addition Bearing Wear Monitoring (BWM),
Main Bearing Temp. Monitoring (MBTM),Water in Oil Monitoring (WIOM) and
Liner Wall Temperature (LWT) systems are
essential tools
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Bearings, CBO overhaul / open-up criteria:
Main bearings should only be opened in case of alarm.
Check every 3 month:
Clearance and deflexion readings.
Bearing edges to be checked by wire-feeler formissing- or squeezed-out metal
All parts of the crank case to be checked for loose metal.
Con. rod- and x-head bearings:
Random open up inspection at the 5 year's docking,
and in case of external indications
Condition Based Overhaul (CBO)
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Condition Based Overhaul (CBO)
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Condition Based Overhaul (CBO)
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Modern MAN BW 2-stroke
engines are designed to
extended TBO by means of:
Slide fuel valves
Nimonic- or Dura spindles
W-seat
Oros combustion Chamber,
formed entirely in steel as a
result of
low positioned matingsurface
Low positioned ring packages
Heavy dutyring packages
Optimised liner temperature
Condition Based Overhaul (CBO)
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Nimonic spindle & W-seat,
S60MC, 25.500 service hrs
Dura Spindle & W-seat,
S60MC, 40.042 service hrs
(DuraSpindle seat welded on Nimonic spindle)
Condition Based Overhaul (CBO)
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Modern MAN BW 2-stroke
engines are designed to
extended TBO by means of:
Slide fuel valves
Nimonic- or Dura spindles
W-seat
Oros combustion Chamber,
formed entirely in steel as a
result of
low positioned matingsurface
Low positioned ring packages
Heavy dutyring packages
Optimised liner temperature
Condition Based Overhaul (CBO)
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When is piston overhaul needed?
Before piston burning reach 15
mm
Condition based piston overhaul
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Condition Based Overhaul (CBO)
Still rounding
Still rounding
Still rounding
Still roundingCBO example:
10K98MC-C, unit 7, 23,597 hours
without overhaul.
Note, visual good condition,
without being perfect.
Is it due for overhaul?
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Status
Fig. 3. Totally scuffed unit. Lubrication should beincreased to maximum until overhaul is convenientwith regard to the schedule of the ship. Due to thefriction heat developed, the piston rings get hardened,and the wear rate of the liner increases significantly.However, the hardening protects the rings, which iswhy the operation may be continued safely until nextconvenient port stay.
Fig. 4. Unit with micro-seizures on the top ring as aresult of metal-to-metal contact. Should be counter-acted by temporarily increased lubrication. It isimportant to lower the lubrication to normal as soonas the active mz-attack is stopped. Note that old, notactive, mz-marks remain visible long after the attackhas stopped and do not call for increased lubrication.
Fig. 5. Unit with 23,500 hours without piston overhaul.Note that most of the rounding is still intact, indicatingthat only of the wear potential is used. Further, themeasurements above from the same unit shows thatonly of the ring groove wear potential is used, andthe rate of burnings on the piston top is insignificant.Consequently, overhaul of that unit is not needed atthis stage.
Visual inspection of piston rings (cermet-alu coated top ring)
Condition Based Overhaul (CBO)
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Status
Fig. 6. Totally scuffed unit. Lubrication should beincreased to maximum until overhaul is convenientwith regard to the schedule of the ship. Due to thefriction heat developed, the piston rings get hardened,and the wear rate of the liner increases significantly.However, the hardening protects the rings, which is
why operation may be continued safely until nextconvenient port stay.
Fig. 7. Unit with micro-seizures on the top and bottomrings as a result of metal-to-metal contact. Should becounteracted by temporarily increased lubrication. Itis important to lower the lubrication to normal as soonas the active mz-atack is stopped. Note that old, notactive, mz-marks remain visible a long time and do
not call for increased lubrication.
Fig. 8. Unit running very well after 20,021 runninghours. Note that the last remains of the alu-coat arestill visible on the lower edge, indicating remainingrounding left. This means that the ring wear is lessthan 2 mm out of possible 3 mm. Consequently,many more hours are left from the point of view of
wear.
Visual inspection of piston r ings (all alu-coated)
Condition Based Overhaul (CBO)
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Condition Based Overhaul (CBO)
Scuffingw
ear
Polishedw
ear
Adhesive
wear
Normalcorrosive
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Condition Based Overhaul (CBO)
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Cylinder ConditionReport - la...
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4.8 mm
When is piston overhaul needed?
3 mm
Condition Based Overhaul (CBO)
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Cylinder Lubrication, latest experience
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Testing flat rate at 0.50 g/kWh abs.
8S60MC Car-carrierHigh topland pistonAlu-coated CPR piston ringsSlide fuel valve
Low cyl. oil dosages 0.50 g/kWh the last6,805h on 4 cylinders
Piston (number 1) never pulled (picture takenat 42,773 ring hours after running 0.55 g/kWh!)Piston number 1 has now just passed 50,000hours without overhaul.
Cylinder Lubrication, latest experience
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Overhaul Strategy on MAN B&W 2Stroke Engines :
Tankers:
9To limi t overhauls and inspections by means of extended engine monitoring
93 / 5 year overhaul intervals, to coincide with Class-Dockings, are presently possible
on engines with the newest design.
Container and Bulk Carriers:
9To limit overhauls / inspections by means of Condition Based Overhaul (CBO),
whereby the average TBO of the main components can be increased
up to 5 years.
Condition Based Overhaul (CBO)
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Overhaul Strategy on MAN B&W 2Stroke engines
9Expect all pistons to be fully reconditioned
by re-welding and re-chroming9 Heavy duty Piston Ring Packages
9Extended engine monitoring
9Intensified engine survey
(scavenge port inspections)
Condition Based Overhaul (CBO)
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Overhaul Strategy on MAN B&W 2Stroke engines
Quality requirements for significantly Extended TBO of the Cylinder Units:
9Sophisticated Piston Ring Packages require high manufacturing quality
9Recondit ioning of piston crowns requires high quality from an authorised work
shop
9The piston overhaul jobs require high quality, also regarding the reporting
9Intermediate inspections require qualified engineers and reporting
Condition Based Overhaul (CBO)
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Service Versus
Advantage of Maintenance contracts
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MAN Diesel
PrimeServ
Copenhagen
Spare
Parts
Upgrades
Special
Projects
Technical
Service
Diesel
Academy
Service Versus
Engine Management Concept
Advantage of Maintenance contracts.Engine Management Concept
Advantage of Maintenance contracts
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Advantage of Maintenance contracts.EMC overview
(1) MAN Diesel conducts the complete logistic works
Advantage of Maintenance contracts.
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Advantage of Maintenance contracts.Maintenance Schedule
Advantage of Maintenance contracts.
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gMachinery Otimisation
Advantage of Maintenance contracts.
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gEngine Performance
Action:
Observe any abnormality by daily checks of engine parameters.
Maintain full engine performance report twice every month
Evaluate all obtained engine data carefully and compare with earlier data / shop
test / sea trial data.
Benefits:
Safe and Reliable Engine.
Low Maintenances Cost.
Optimum Plant Economy
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Questions?
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